Connecting arrangement for multiconductor cables

ABSTRACT

A trunk cable has its end fitted with a multicontact plug that is held in a frame member of a connecting arrangement. A similar multicontact plug is fitted to each branch cable, and is held next to the trunk plug with all the plug contacts exposed on one face of the frame member. At least one jack body can be fitted over all the exposed contacts to couple the trunk cable conductors to those of the branch cables. A cover is hermetically attached to the frame member to cover the jack body and all of one face of this frame member. The plug casings have their edges soldered together and the wires leading away from them are potted with insulating resin in lead shells or synthetic resin shells which are sealed to the casings so that the entire coupling arrangement is fully sealed, while the connections can be easily changed by removing and replacing the upper plug bodies.

United States Patent Staudt Y May 2,1972

[72] Inventor:

. [54] CONNECTING ARRANGEMENT FOR MULTICONDUCTOR CABLES Markus Staudt, Basel, Switzerland [73] Assignee: Neidecker 8; Co., Basel, Switzerland [22] Filed: Mar. 20, 1970 [21] Appl. No.: 21,458

[58] Field of Search ..339/l54, 222, 19, 148, I26, 339/121, 18, 28, 29, 37, 157, 59, 60; 174/37, 60

[56] References Cited UNITED STATES PATENTS 3,227,989 1/1966 Wilm et a1 ..339/l2l X FOREIGN PATENTS OR APPLICATIONS 647,783 8/1928 France 1 74/60 Primary Examiner-Richard E. Moore Attorney-Karl F. Ross [57 ABSTRACT A trunk cable has its end fitted with a multicontact plug that is held in a frame member of a connecting arrangement. A similar multicontact plug is fitted to each branch cable, and is held next to the trunk plug with all the plug contacts exposed on one face of the frame member. At least one jack body can be fitted over all the exposed contacts to couple the trunk cable conductors to those of the branch cables. A cover is hermetically attached to the frame member to cover the jack body and all of one face of this frame member. The plug casings have their edges soldered together and the wires leading away from them are potted with insulating resin in lead shells or synthetic resin shells which are sealed to the casings so that the entire coupling arrangement is fully sealed, while the connections can be easily changed by removing and replacing the 7 upper plug bodies.

10 Claims, 7 Drawing Figures PATENTEUMY 21912 v INVENTOR.

MARKUS STAUDT ATTORNEY PATENTEBMY 2 m2 SHEET 3 BF 3 FIG.6

FIG.7

FIG.4

INVENTOR.

MARKUS STAUDT ATTORNEY CONNECTING ARRANGEMENT FOR MULTICONDUCTOR CABLES FIELD OF THE INVENTION The present inventionrelates to a connecting arrangement for multiconductor cables, particularly for connecting a telephone trunk line to one or more branch cables.

BACKGROUND OF THE INVENTION Customarily, the outer layer of insulation is removed from v the truck line, then the conductors are individually stripped and the conductors of the branch line are spliced to them. If the trunk line itself is going to be split, its end is opened and its individual conductors must be stripped and spliced to the stripped conductors of the branch lines. Thereafter, the entire assembly must be wrapped with insulating material and encased in a lead sleeve which is hermetically sealed. This process is extremely lengthy, and requires the work of highly trained and well paid service personnel.

In orderto change such a setup at a later date, the entire arrangement must be opened, and the necessary wires found and reconnected to new circuits as desired. Once again, the cost is high, skilled workers are required, etc.

OBJECTS OF THE INVENTION 7 It is, therefore, an object of the present invention to provide an improved connecting arrangement for multiconductor wires. In particular the present invention is aimed at improvements in connections of telephone cables, although it is by means limited to such multiconductor cables.

Another object is to provide such a connecting arrangement which allows the simple and easy connection of trunk and branch cables, while making it easy to convert an old connection of, say, one trunk cable to a particular number of branch cables to an arrangement connecting this trunk cable to more or fewer branch cables, without the necessity of highly skilled personnel.

SUMMARY .OF THE INVENTION The above objects are attained, in accordance with a feature of the present invention by a connecting arrangement having at least two coupling elements each mounted on an end of one multiconductor cable and each carrying an array of contacts which are respectively connected to conductors of the respective cables. A substantially planar mounting or frame member is provided which holds the elements next to each other, with the contacts exposed on one side of the plane and the cables leading away from the other side thereof. At least two coupling bodies each having an array of contacts are engageable from the other side of the plane with the contacts on the cable elements, and electrical conductors extend between these contacts on the coupling bodies to couple the cables together. The coupling bodies are removable so that by changing one body for another the connections between trunk and branch cable are easily changed.

According to another feature of the present invention the frame member is formed with an annular channel into which fits the edge of a cup-shaped cover that has an outwardly extending flange that can be clipped to an outwardly extending flange on the channel so that the coupling bodies can be hermetically sealed in.

In accordance with yet another feature of this invention the coupling elements can be fitted together in the frame member in a multitude of patterns, with filling plates closing the unused areas so that the arrangement is flexible in the extreme.

Thus, the basic structure of the present invention comprises a generally planar frame of nonoxidizable metal (e.g. aluminum or steel coated with tin or zinc to facilitate soldering) or some other metal coated with a scalable synthetic resin or even composed entirely thereof, into which are fitted a multiplicity of codirectionally open casings, frames or troughs of similar compositions, the latter casings being widened at their mouths and sewing to accommodate multicontact arrays or plugs as will be apparent hereinafter. Along their upper lips, the modular casings are soldered or heatsealed together and to the frame. Some of the casings may be blind (i.e. unperforated or closed at their bases which are coplanar with the bottom of the frame while their lips may be flush i.e. coplanar) with the top of the frame, whereas others are open to accommodate the plugs or conductors and any leads running to them. The multicontact arrays of the trunk line plugs and the multicontact arrays of the branch lines consist of arrays of contacts potted or embedded in insulating synthetic resin and seated against the bases of the respective casings while being recessed below the lips thereof, the contacts of both trunk and branch lines being coplanar and disposed side-by-side in the unit formed by the frame and casings. Any gaps in the opening enclosed by the frame may be filled by modular plates of similar construction which are soldered or heatsealed to the frame and any adjoining casings.

Electrical connection between the branch and the truck line multicontact arrays is made by prewired socket bodies, each consisting of a multicontact array embedded in insulating synthetic resin and recessed in an upper, but downwardly open, casing adapted to register with the upwardly open lower casing, suitable leads connecting the contacts of the upper casings with one another in accordance with the desired wiring scheme. Alternatively, the connections may be made by a single upper socket body consisting of a downwardly open casing spanning the entire open space of the frame and having all of its contacts selectively wired and embedded in a monolithic or one-piece body of insulating synthetic resin.

The frame is, moreover, composed of an upwardly open channel running entirely around the periphery of the space enclosed by the frame and receiving a hermetically sealing mass or layer which engages an all-around peripheral lip of a cover which closes the unit and is detachably secured to the frame. This cover may be deep drawn to accommodate the upper casings or casing as noted earlier and is composed of a material akin to that of the frame and casings.

To complete the hermetic seal of the unit, each of the cables, i.e. the branch and trunk lines, may be provided with a lead sheath as is customary in many areas, whereupon the respective junction with the plug is made with a one-piece lead shell soldered to the sheath and soldered to the respective plug casing. When, of course, the insulating sheath surrounding the cable is composed of synthetic resin, the shell may be of like composition and heatsealing solvent welding or cement is used to join shell to casing and sheath to shell. The space between the shell and the conductors and the interstices between the conductors is filled with a hardenable insulating resin cast in place prior to or after the shell is sealed to the casing.

Not only does the aforedescribed structure greatly accelerate and simplify the wiring of distribution junctions and prevent wiring mistakes while affording an opportunity to change the wiring relationships with ease, but the system offers excellent protection against the environment. In practice it has been found that the system can be employed effectively in subterranean ducts, cellars, manholes and the like, as well as in on-the-ground and in above-ground systems. While preeminently successful for telephone cable, it has been found to be useful wherever electrical distribution between branch and truck lines may be required, i.e. for electric-current distribution, for measurement and control cables and the like.

DESCRIPTION OF THE DRAWING FIG. 4 is a cross section along line IV-IV of FIG. 2;

FIG. 5 is a perspective view of a contact for a cable according to the present invention;

FIG. 6 is a perspective view of a pair of contacts for the coupling element of this invention; and

FIG. 7 is a detail as indicated by arrow VII of FIG. 5.

SPECIFIC DESCRIPTION There is shown in FIG. 1 a central exchange or station 1 and two substations 2 and 2. A main trunk line 3 of, say, 1,200 conductors extends to the first distributing station 2, from which five branch cables four each of, say, 80 conductors go to the separate users. Another trunk cable (subtrunk) 5 of only, for example, 800 conductors leads to the other substation 2', from which again five 8O conductor cables 4 lead away.

As seen in FIG. 2, the connecting arrangement consists basically of a frame member 7 in which are received a plurality of plug-and-socket elements 8 formed by plug elements 9 mounted on the ends of the cables 3, 4 and socket elements 10 which serve to connect these cables together as will be described below.

Each coupling element consists of a trough-like metallic body 18 (of a nonoxidizing material such as aluminum) which is formed in its base with an array of holes 26 (See FIG. 4). Adapted to be received in these bodies 18 with clearances filled with insulating material are contacts as shown at 11 in FIG. 5. The bodies 18 may also be constituted as frames into which multicontact arrays cast in synthetic resin may be fitted. Each contact 11 has a conductive core 32 terminating at one end in a U-shaped clip 27 with small inwardly protruding tabs 28. These clips 27 are received in U-shaped synthetic-resin bodies 29 which are molded with a stem 30 having a frustoconical collar 31. The stem 30 is dimensioned to fit snugly in the holes 26 so that they can be pushes therethrough and are prevented from being withdrawn by the collars 31.

The core 32 is cut out at 23 (FIG. 7) with a rectangular window 33 formed by a pushed-in flap 34. A conductor 6 of one of the cables is pushed into the hollow core 32, of square cross section, and soldered to the flap 34, after the contact 11 has been pushed through one of the holes 26 in the body 18. These holes 26 are arranged in a regular array so that the contacts are evenly ordered. After a contact 11 has been soldered to each conductor 6 of one of the cables 3, 4, a lead sleeve 25, which has already been slipped over the cable end is slid down over the body 18. To this end the trough-like body 18 is stepped at 35 and has a narrow lower region 26 that snugly receives the sleeve 25. The contacts 11 are then potted in the sleeve 25, in insulating synthetic resin (e.g. a silicone or epoxy) as shown at 24. FIG. 3 shows the finished array of contacts at 20. The sleeves may, alternately, be composed of synthetic resin (e.g. polypropylene or polyethylene) which is heatsealed to the thermoplastic sheath of the cable and then bonded hermetically to the casings 18 which may be coated externally with a similar antioxidation covering.

After assembly of a coupling element 22 at the end of each cable 3, 4, the bodies 18 are soldered together, one next to each other, along their upper edges 37, and to the frame element 7. Gaps remaining in the frame element 7 are filled by plates 19 or blind (unperforated) casings 18 so that no hole remains for passage of liquid or gas through the frame member 7. The bodies 18 and 19 are of modular dimensions with respect to the frame area so that, for example, two, three, five, ten or twenty such bodies may be accommodated therein.

This frame member 7 is formed with a U-shaped channel 14 all around its periphery, in which is provided a seal 16 which is preferably a long-lasting type of putty, e. g. a silicone or polyurethane. A rectangular, box-like cover 13 has a lower edge 38, projecting beyond the laterally projecting coupling flange, which is receivable in this annular channel 14, and imbeddable in the putty 16 to hermetically seal the contacts from above. This cover 13 has a flange 15 which registers with an outwardly extending all-around peripheral flange 15 on the frame 7, a resilient seal 39 being provided between them. Clips 17 can be slipped over the two flanges 15 and 15' to hold the cover tightly in place.

In order to connect the cables 3 and 4 together, upper socket portions 10 are provided. As shown in FIG. 6, these comprise a plurality of contacts 12 formed much as the contacts 11 except that they have upper lug portions 40 formed with holes 41 adapted to receive wires as shown at 42 in FIG. 3. These contacts 12 are preassembled into units 21 at the factory, with the upper ends being covered and protected by a metallic shell 44. Of course, a single unit 21 can be used, which has a size equal to the entire area of the frame 7, and whose wires are all imbedded in synthetic resin (e.g. a silicone or epoxy) to conceal and protect them, while insulating the contacts from one another.

FIG. 6 shows how two contacts 12 can be fixed together. Such an arrangement is also useful for the contacts 11, since most telephone wires consist of pairs which are associated with the same devices or functions. Of course, bipolar contacts, i.e. individual contacts with two contact surfaces each insulated from the other, can be provided for connection with two conductors, if desired.

The arrangement of the present invention is used as follows:

Once the main cable 3, prefitted with the plug body 20, is run to the point at which it is to branch, all the branch cables are also fitted with similar plugs 20, with lesser number of contacts, and all the trough-like bodies 18 and plates 19 are soldered together, in the frame 7. Then a set of prepared plugs 21 is fitted to the tops of the rows of contacts 11 to connect up the cables 3, 4 as desired, or a single prewired plug is fitted over the entire frame 7. A subtrunk cable with similar plug may also be received in the latter. Thereafter, the cover 13 is fitted over the frame 7.

Of course, to add or subtract a branch (or to change the connections) in such a connecting arrangement, the cover 13 need merely be removed and the plug 21 pulled off. A replacement plug can then be substituted and the cover closed. If necessary, the body 18 can be unsoldered and the hole filled by a plate 19, or vice versa. A new plug 21 can thereupon be simply fitted to the arrangement to set up the connections as desired.

ICLAIM:

1. A connecting arrangement for at least two multiconductor cables, said arrangement comprising:

at least two coupling elements each mounted on an endof one of said cables and each carrying an array of contacts, each contact being electrically connected to a respective one of said conductors;

a substantially planar mounting member holding said elements next to each other with said contacts in substantially the same plane, said cables extending away from said contacts on one side of said plane and said contacts being exposed on the other side thereof;

at least two coupling bodies each provided with an array of contacts engageable from said other side of said plane with said first-mentioned contacts on said coupling element;

a plurality of electrical connectorseach extending between a contact on one of said bodies and a contact on the other of said bodies, whereby said conductors of one of said cables are individually electrically connected to said conductors of the other of said bodies; and

a cover and means for sealingly engaging said cover with said member and hermetically enclosing said bodies and said connectors between said member and said cover,

said member and said cover being formed with like registering outwardly extending respective flanges, said means including at least one clip engageable with said flanges for holding same together.

2. The arrangement defined in claim 4 wherein said member is formed with a peripheral annular channel, said cover having an edge engageable in said channeL'said means including a flexible seal in said channel engageable with said edge.

3. The arrangement defined in claim 2 wherein said member is elongated, a plurality of said elements being provided with at least two rows transverse to the axis of said member, and two rows in line with said axis.

4. The arrangement defined in claim 4 wherein said contacts of each element are all unitarily imbedded in said element.

5. Aconnecting arrangement for at least two multiconductor cables, said arrangement comprising:

at least two coupling elements each mounted on an end of one of said cables and each carrying an array of contacts, each contact being electrically connected to a respective one of said conductors;

a substantially planar mounting member holding said elements next to each other with said contacts in substantially the same plane, said cables extending away from said contacts on one side of said plane and said contacts being exposed on the other side thereof;

at least two coupling bodies each provided with an array of contacts engageable from said other side of said plane with said first-mentioned contacts on said coupling elements;

a plurality of electrical connectors each extending between a contact on one of said bodies and a contact on the other of said bodies, whereby said conductors of one of said cables are individually electrically connected to said conductors of the other of said bodies; and

at least one plate connected to said frame between said elements and said frame, said frame, plate, and elements forming a continuous unperforated surface.

6. The arrangement defined in claim 5 wherein said frame and said elements are made of a nonoxidizable material.

7. The arrangement defined in claim 6 wherein said contacts of each element are all unitarily imbedded in said element.

8; The arrangement defined in claim 5 wherein said member is elongated and has an axis, a plurality of said elements being provided with at least two rows transverse to the axis of said member, and two rows in line with said axis.

9. A connecting arrangement for at least two multiconductor cables, said arrangement comprising:

at least two coupling elements each mounted on an end of one of said cables and each carrying an array of contacts, each contact being electrically connected to a respective one of said conductors;

a substantially planar mounting member holding said elements next to each other with said contacts in substantially the same plane, said cables extending away from said contacts on one side of said plane and said contacts being exposed on the other side thereof;

at least two coupling bodies each provided with an array of contacts engageable from said other side of said plane with said first-mentioned contacts on said coupling elements;

a plurality of electrical connectors each extending between a contact on one of said bodies and a contact on the other of said bodies, whereby said conductors of one of said cables are individually electrically connected to said conductors of the other of said bodies; and

a box-like cover, said member and said cover being formed with similar outwardly extending flanges, said member being formed with a peripheral annular U-shaped channel, said cover having an edge engageable in said channel, said cover and said member being provided with a seal between said flanges and in said channel; and

a plurality of substantially U-shaped spring clips engageable over said flanges.

10. A connecting arrangement for at least two multiconductor cables, said arrangement comprising:

at least two coupling elements each mounted on an end of one of said cables and each carrying an array of contacts, each contact being electrically connected to a respective one of said conductors; a substantially planar mounting member holding said elements next to each other with said contacts in substantially the same plane, said cables extending away from said contacts on one side of said plane and said contacts being exposed on the other side thereof;

at least two coupling bodies each provided with an array of contacts engageable from said other side of said plane with said first-mentioned contacts on said coupling elements;

a plurality of electrical connectors each extending between a contact on one of said bodies and a contact on the other of said bodies, whereby said conductors of one of said cables are individually electrically connected to said conductors of the other of said bodies, each of said elements including a through-like metallic body having an array of perforations, at least one of each of said contacts for said cable conductors being arranged in each of said perforations, said trough-like metallic body being of narrowed width toward said perforations; and

a sleeve engageable over said metallic body at the narrowed region thereof. 

1. A connecting arrangement for at least two multiconductor cables, said arrangement comprising: at least Two coupling elements each mounted on an end of one of said cables and each carrying an array of contacts, each contact being electrically connected to a respective one of said conductors; a substantially planar mounting member holding said elements next to each other with said contacts in substantially the same plane, said cables extending away from said contacts on one side of said plane and said contacts being exposed on the other side thereof; at least two coupling bodies each provided with an array of contacts engageable from said other side of said plane with said first-mentioned contacts on said coupling element; a plurality of electrical connectors each extending between a contact on one of said bodies and a contact on the other of said bodies, whereby said conductors of one of said cables are individually electrically connected to said conductors of the other of said bodies; and a cover and means for sealingly engaging said cover with said member and hermetically enclosing said bodies and said connectors between said member and said cover, said member and said cover being formed with like registering outwardly extending respective flanges, said means including at least one clip engageable with said flanges for holding same together.
 2. The arrangement defined in claim 4 wherein said member is formed with a peripheral annular channel, said cover having an edge engageable in said channel, said means including a flexible seal in said channel engageable with said edge.
 3. The arrangement defined in claim 2 wherein said member is elongated, a plurality of said elements being provided with at least two rows transverse to the axis of said member, and two rows in line with said axis.
 4. The arrangement defined in claim 4 wherein said contacts of each element are all unitarily imbedded in said element.
 5. A connecting arrangement for at least two multiconductor cables, said arrangement comprising: at least two coupling elements each mounted on an end of one of said cables and each carrying an array of contacts, each contact being electrically connected to a respective one of said conductors; a substantially planar mounting member holding said elements next to each other with said contacts in substantially the same plane, said cables extending away from said contacts on one side of said plane and said contacts being exposed on the other side thereof; at least two coupling bodies each provided with an array of contacts engageable from said other side of said plane with said first-mentioned contacts on said coupling elements; a plurality of electrical connectors each extending between a contact on one of said bodies and a contact on the other of said bodies, whereby said conductors of one of said cables are individually electrically connected to said conductors of the other of said bodies; and at least one plate connected to said frame between said elements and said frame, said frame, plate, and elements forming a continuous unperforated surface.
 6. The arrangement defined in claim 5 wherein said frame and said elements are made of a nonoxidizable material.
 7. The arrangement defined in claim 6 wherein said contacts of each element are all unitarily imbedded in said element.
 8. The arrangement defined in claim 5 wherein said member is elongated and has an axis, a plurality of said elements being provided with at least two rows transverse to the axis of said member, and two rows in line with said axis.
 9. A connecting arrangement for at least two multiconductor cables, said arrangement comprising: at least two coupling elements each mounted on an end of one of said cables and each carrying an array of contacts, each contact being electrically connected to a respective one of said conductors; a substantially planar mounting member holding said elements next to each other with said contacts in substantially the same plane, said cables extending away from said contacts on one side of said plane and said coNtacts being exposed on the other side thereof; at least two coupling bodies each provided with an array of contacts engageable from said other side of said plane with said first-mentioned contacts on said coupling elements; a plurality of electrical connectors each extending between a contact on one of said bodies and a contact on the other of said bodies, whereby said conductors of one of said cables are individually electrically connected to said conductors of the other of said bodies; and a box-like cover, said member and said cover being formed with similar outwardly extending flanges, said member being formed with a peripheral annular U-shaped channel, said cover having an edge engageable in said channel, said cover and said member being provided with a seal between said flanges and in said channel; and a plurality of substantially U-shaped spring clips engageable over said flanges.
 10. A connecting arrangement for at least two multiconductor cables, said arrangement comprising: at least two coupling elements each mounted on an end of one of said cables and each carrying an array of contacts, each contact being electrically connected to a respective one of said conductors; a substantially planar mounting member holding said elements next to each other with said contacts in substantially the same plane, said cables extending away from said contacts on one side of said plane and said contacts being exposed on the other side thereof; at least two coupling bodies each provided with an array of contacts engageable from said other side of said plane with said first-mentioned contacts on said coupling elements; a plurality of electrical connectors each extending between a contact on one of said bodies and a contact on the other of said bodies, whereby said conductors of one of said cables are individually electrically connected to said conductors of the other of said bodies, each of said elements including a through-like metallic body having an array of perforations, at least one of each of said contacts for said cable conductors being arranged in each of said perforations, said trough-like metallic body being of narrowed width toward said perforations; and a sleeve engageable over said metallic body at the narrowed region thereof. 